机器人点焊板材厚度检测的数值模拟与变量程序应用研究  

Research on Variable Program Application of Plate Thickness Detection in Robot Resistance Spot Welding

作　　者：卢健能 柯世金 谈毅 罗邦芬 LU Jianneng;KE Shijin;TAN Yi;LUO Bangfen(School of Mechanical Engineering,Guangzhou City University of Technology,Guangzhou 510800,China)

机构地区：[1]广州城市理工学院机械工程学院,广东广州510800

出　　处：《电焊机》2024年第6期39-44,共6页Electric Welding Machine

基　　金：2022广东省教育科学规划课题(高等教育专项)(2022GLK388)。

摘　　要：针对轿车车门内板点焊过程中,机器人伺服焊枪经过多个焊点操作后工件间隙扩大,以及钣金厚度变化造成的焊接质量下降问题。基于ANSYS有限元技术对高强度双相钢机器人点焊过程进行热传导数值模拟分析,研究板材厚度变化对焊接热传导效率及熔核直径大小的影响。试验结果表明,当板材厚度为1.9~2.0 mm时,熔核直径达到最大值,随着板材厚度的增加,熔核直径减小,焊接质量下降。为解决这一问题,运用KUKA机器人伺服焊枪的板材厚度动态检测功能和变量程序跳转指令,在板材厚度超出公差值(1.8~2.5 mm)时中断机器人焊接程序并及时报警,减少了板材间隙增大带来的飞溅、虚焊等缺陷,提高形核质量和焊接精度,保证车门内板高强度双相钢点焊的前后焊点质量稳定。This study addresses the issue of welding quality degradation in the spot welding process of car door inner panels,where the gap between workpieces expands and the sheet metal thickness changes after the robot servo welding gun passes through multiple welding points.Based on ANSYS finite element technology,a thermal conduction numerical simulation analysis of the robot spot welding process for high-strength dual-phase steel was conducted to investigate the impact of plate thickness variation on welding heat conduction efficiency and nugget diameter size.The experimental results indicate that when the plate thickness is between 1.9~2.0 mm,the nugget diameter reaches its maximum value,and as the plate thickness increases,the nugget diameter decreases,leading to a decline in welding quality.To resolve this issue,the dynamic detection function of the KUKA robot servo welding gun for plate thickness and the variable program jump command were utilized.When the plate thickness exceeds the tolerance value(1.8~2.5 mm),the robot welding program is interrupted and an alarm is issued in a timely manner,reducing defects such as spatter and false welding caused by the increase in plate gap,and improving nucleation quality and welding precision,thus ensuring the stability of the front and back welding points'quality in the spot welding of high-strength dual-phase steel for car door inner panels.

关 键 词：机器人点焊 板材厚度 熔核直径 热传导模拟 变量程序 

分 类 号：TP438.2[自动化与计算机技术]